Integrated ceiling system

ABSTRACT

The present invention is directed to an integrated ceiling system of the electrified hung ceiling type, characterized by ease of installation, flexibility, structural rigidity and aesthetic appearance. The ceiling includes longitudinally extending runners, transversely extending tile supports and locking struts which interfit between adjacent runners, rigidly coupling the same. A characterizing feature of the structure lies in the novel attachment elements which enable the parts to be accurately and easily integrated.

United States Patent 1 1 Donate Aug. 12, 1975 [5 INTEGRATED CEILING SYSTEM 3.640.042 2/[972 Kidney 52/496 x 3,677,589 7/1972 R l [75] Inventor: Anthony C. Donate, Westfield. NJ 3 685235 8/1972 2 73 Assignee: Lightoliel. lncorporaed Jersey Cityv 3,798,865 3/l974 Curtis I. 52/488 X Primary ExaminerPrice C. Faw. Jr. [22] Flled' 1974 Attorney, Agent, or FirmArthur B. Colvin [2|] Appl. No.: 430,913

[57] ABSTRACT [52] 52/488; g i z t The present invention is directed to an integrated ceil- 2 ing system of the electrified hung ceiling type, characg gr i 2 terized by ease of installation, flexibility, structural ri- 1 668 1 gidity and aesthetic appearance. The ceiling includes longitudinally extending runners, transversely extending tile supports and locking struts which interfit be- [56] References cued tween adjacent runners. rigidly coupling the samev A UNITED STATES PATENTS characterizing feature of the structure lies in the novel 1,l65,049 l2/l9l5 White 52/758 A attachment elements which enable the parts to be ac- 2,873,828 2/l959 Zitomerm 52/668 X urately and easily integrated 3,32I,879 5/l967 Purdy 52/573 X 3,352,071 [1/1967 Sutter 52/484 X 3 Claims, 14 Drawing Figures INTEGRATED CEILING SYSTEM BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention is in the field of so-called hung" ceilings, referring to a grid work depending from the structural components of the building, the grid work being of the electrified type, and being adapted to support ceiling tiles as well as lighting fixtures and like devices which may derive power from the electrified components carried by the ceiling grid.

2. The Prior Art It is known to provide metallic structures which depend from the ceiling of a room, which structures form the mounting means for lighting fixtures and ceiling tiles, such that the ceiling of the room presents an attractive appearance.

It is likewise known to incorporate within the tile supporting gridwork electrical conductors which are accessible from below the ceiling, the conductors permitting various electrical appliances, such as spotlights, for example, to be clamped to the ceiling structure, affording both a mechanical and electrical connection without the necessity for independent wiring.

A drawback of such known electrified ceiling constructions is that their installation requires the presence of highly skilled workers since a substantial amount of on site cutting and fitting of components is required.

SUMMARY The present invention is directed to an improved electrified ceiling grid system wherein a minimum number of stock parts is required, the parts being readily interconnected into a rigid, durable, versatile and attractive ceiling system.

The ceiling structure is comprised of a perimeter which is first affixed to the vertical wall structures of a room within which the ceiling is to be applied. Longitudinal runners are thereafter secured in position, the ends of the runners adjacent the perimeter being se' cured thereto. The runners are additionally provided along their length with the usual wire support hangers. Abutting ends of runners may be mechanically and electrically interconnected by novel mechanical connector elements which may carry an electrical junction box, the connectors being insertible into position by a sidewise or rolling action, whereby the spreading or canting oflongitudinal elements, as required in installations heretofore known, may be obviated.

Additionally, a novel system of transverse tile support and rigidifying strut components is provided whereby the transverse tile supporting members may be inserted into position to define a flexible temporary gridwork before adjacent longitudinal runners are locked against transverse movement, by the application of transverse locking struts.

The tile support hangers include novel coupling means which permit relative movement between abutting hangers, until the final or locking positioning of the parts is established by application of the transverse support struts.

The runners include prepunched slots and apertures which establish the spacing of the support ledges and struts in accordance with the size of the tiles to be employed, whereupon accurate positioning of the parts is assured with a minimum of on site measurements or adaptation.

Accordingly, it is an object of the present invention to provide an improved ceiling grid construction for a hung ceiling installation.

It is a further object of the invention to provide a grid structure of the type described wherein installation is facilitated by reason of the fact that a substantial number of the installing steps may be carried out after the main structural components, namely, the longitudinal runners, have been mounted in position, the runners being relatively movable until the final grid structure is assembled, such final assembly being effected without the necessity of using tools, tightening of bolts, screws, etc., the assembly merely requiring insertion of transverse support struts and rotation of the struts into locking position.

A further object of the invention is the provision of a ceiling grid structure of the type described having sufficient rigidity to permit the ceiling structure to be used as an anchoring point for vertically extending columns, display rods or the like.

It is still a further object of the invention to provide a ceiling grid construction of the type described wherein the transverse tile support members incorporate novel interconnection means, greatly facilitating assembly of the members in a manner permitting relative movement of the members until the components are locked into position.

It is still a further object of the invention to provide an assembly of the type described wherein certain of the longitudinally extending runners may include polar ized electrical conductors, the apparatus including means for securing a junction box between the ends of adjacent runners, the junction box including coded connector means permitting the junction box to be inserted between adjacent runners only if the runners are properly aligned.

To attain these objects and such further objects as may appear herein or be hereinafter pointed out, refer ence is made to the accompanying drawings, forming a part hereof, in which:

FIG. 1 is a fragmentary perspective view of a ceiling structure in accordance with the invention;

FIG. 2 is a fragmentary magnified sectional view taken on the line 2-2 of FIG. 1;

FIG. 3 is a top plan view taken in the direction of the arrow 33 of FIG. 2;

FIG. 4 is a magnified perspective view showing details of the connection between adjacent tile support hangers with the longitudinally extending runner;

FIG. 5 is a section taken on the line 55 of FIG. 2;

FIG. 6 is a vertical section taken on the line 66 of FIG. 2.

FIGS. 7 and 8 are perspective views of the connection between the transverse cross struts and longitudinal runners, showing the components respectively in the pre-assembled and post-assembled condition;

FIG. 9 is a vertical section taken on the line 9-9 of FIG. 8;

FIG. 10 is a horizontal section taken on the line l0I0 of FIG. 9;

FIG. 11 is a detail view showing the means of anchoring the end of a runner to the perimeter;

FIG. 11a is a sectional view taken along line Ila-l Ia of FIG. 11;

FIG. 12 is a perspective view of a mechanical connection between adjacent runner sections including a junction box installed between the ends of adjacent longitudinal runners; and

FIG. 13 is a view of the mechanical connector with the runner sections and junction box removed.

Turning now to the drawings, there is shown in FIG. I a hung ceiling structure in which a plurality of tiles T are supported from a gridwork assembly 10. The grid assembly includes a plurality of spaced, longitudinally extending runners 11, preferably of extruded aluminum. The terminal ends 12 of the runners 11 are secured to a perimeter member or bracket 13 fixed to the wall structure of a building. The connection of the runher 11 to the perimeter is effected by an end cap member 14 comprising a rigid, metallic element having an inwardly directed tongue 14' matching the cross sectional shape of the internal partial box channel 15 of the runner 11 having inwardly extending flanges 15'.

A lower tongue 14" of insulating material having a boss at its inner end is secured to the upper tongue 14' by machine screw 140 which extends through such boss. Thus, a space S is provided between the adjacent surfaces of the juxtaposed tongues, so that when the tongues are inserted into the box channel 15 as shown in FIG. 1], the flanges 15' will be accommodated in such space S.

In order releasably to lock the end cap member to the channel of runner 11, a screw 14b is provided which extends through an angled threaded hole in tongue 14 as shown in FIGS. 11 and lla and abuts against the side wall of the channel when screw 14b is tightened.

The end cap member includes a locking flange l6, slidably supported within channel 17 formed in the perimeter member by a vertically directed locking bolt 18 passing upwardly through the flange l6 and aperture 19 in the end cap member. A lock nut 20 threaded over the bolt 18 may be tightened to clamp the end cap 14 and, hence, the runner, in an adjusted position along the perimeter member 13.

The runners 11, as is conventional may be supported from the ceiling by a series of hanger wires 2| depending from the ceiling, the wire being passed through apertures formed for the purpose through web 22 of the runner ll.

Optionally. but preferably, one or more of the runners, e.g., the runner 11a, FIG. 2, may include an insulator structure 23 carrying electrical conductors 24, 2S.

Provision is made, as shown in FIG. 12, to connect a junction box 26 to the conductors 24, 25. In order to provide access to the conductors, it is necessary to provide split sections of the runner 11a, the free ends of the runners being clamped to a mechanical connector assembly 27 to which the junction box is secured.

The connector assembly 27 may be formed of cast metal including opposed side faces 28, 29 against which the ends of the respective runner sections may be butted. The connector 27 includes an arcuate upper attachment component 30, the curvature of which intimately fits against the arcuate uppermost portion 31 of the runner. The connector includes a lock shoulder 32 which, in the attached positions, abuts against the vertical face of the web 22 of the runner.

The connector 27 is provided with coded locking projections 33 and 34 adjacent opposite ends thereof, it being observed that the projection 33 is essentially rectangular in vertical section whereas the projection 34 is essentially cylindrical. As previously noted, the runners are pre-punched with various slots and apertures to be hereinafter described. In the course of the pre-punching operation one end (denominated the lead end) of the adjacent runner is provided with a circular aperture 36 adapted to receive the circular projection 34 of the element 27.

The punching of the runners is factory coordinated with the polarity of the conductors 24, 25 and with the connector 27 in such manner that a connector 27 can only couple the adjacent ends of runner sections if the rectangular projectionand circular projections 33, 34 are aligned with comparably shaped apertures 35, 36, respectively. By thus coordinating the punching of the runners and loading of the conductors carried in insulator 23, it is assured that a mechanical connection between adjacent runner sections can be made only if the runners are properly aligned. Otherwise put, if one of the two runner sections were inadvertently rotated through in the horizontal plane, and the conductors carried by the two sections were electrically connected, it would be evident that the conductor 25 of one section would be in alignment with the conductor 24 of the other section. The construction in accordance with the present invention obviates such possibility since, in the event of the reversal of a runner section, as previously described, the abutting ends would have the same shaped apertures, either rectangular or round. In such case, the coded projections 33, 34 would not interfit within the apertures in the runners, whereupon it would be impossible mechanically to interlock the two runners, thus graphically calling to the attention of the installer the error in the positioning of one of the runner sections.

Installation of the connector 27 between adjacent runner sections may be effected without the necessity for spreading the runners, such installation requiring the connector 27 merely to be pivoted about the conforming arcuate configurations of the elements 30 and 31 and simultaneously moved laterally into the position shown in FIG. 12. Thus, the installation of a connector between adjacent runner ends involves a simple pivoting into position of the connector.

The runner ends are provided with locking apertures 37, such apertures preferably including an enlarged clearance portion 38 and a reduced locking portion 39. A machine screw 40 effects the final locking connection with the parts, the machine screw being threadedly received within a complemental aperture formed in the connector 27. It will be appreciated that tightening of the machine screws 40 clamps the components into the desired attached position, and that lateral spreading of the components is resisted not merely by the clamping forces of the screws but by the coded projections 33, 34 which lie in their respective apertures on the runner. Screws 40 also enhance continuity of electrical ground from one runner to the other.

It will be understood that the junction box 26 forms the receptacle for suitable electrical connections E between the main wire M and the conductor in a manner well known in the art.

It will be further understood that connectors 27 are used without junction boxes where it is desired to connect runner ends which do not carry electrical conductors.

After attachment and positioning of the longitudinal runners 11 and 11a in the manner hereinabove set forth, the transverse components forming the integrated gridwork are secured in position. The transverse components are of two basic types, namely. cross tees or tile support hangers 41 which function as mounting supports for the lateral edges of the tiles T, and cross struts 42 which function to lock the cross tees or tile support hangers 41 into position.

The tile support hangers 41 are essentially of inverted T-shape in vertical section (see FIG. 4), including a vertically directed central branch 43 and laterally extending tile support legs 44, 45. The trailing ends 46 of the hangers 41 are provided with female receiver clips 47, the clips 47 including a mounting leg 48 affixed to the branch portion 43 of the hanger.

The mounting leg 48 includes projecting tabs 49, 50, 51, the tabs 49 and 50 overlapping the upper edge of the hangers, the tab 51 extending through a transverse slot 52 formed in the adjacent end of the hanger or tee. A rivet member 53 secures the female clip 47 in position, the interconnection of the tabs 49, 50 and S1 and the adjacent components of the cross thus precluding any substantial pivotal movement of the clips.

The leading edges 54 of the cross Tees or hangers are provided with a male clip component 55, including an attachment leg 56 carrying locator tabs 57, 58, 59. The tab 59 extends through a locator slot 60 adjacent the end 54 of the hanger, the tabs 57, 58, 59 functioning in the manner described in connection with tabs 49, 50, 51 to prevent relative pivotal movement between the male clip component, which component is held in position on the hanger by the rivet 61.

The female clip component 47 includes a receiver socket 62 generally in the form of an inverted U. The clip 55 includes an elongated alignment finger 63 adapted to be intimately received within the socket 62 of the female clip.

The runners 11 are, as previously noted, pre-punched through the web 22 to define spaced vertical slots 64, the spacing of the slots being calculated to equal the width of the tiles T. As best understood from a consideration of FIGS. 4, 5 and 6, the elongated finger 63 of cross T 41a is passed through the slot 64 of the runner 11 until edge 54 abuts against edge 54' of flange 65a of runner 11 and the edge 63' of member 55 rests on flange 65a.

At this time, the adjacent cross T 41b is positioned at an angle as shown in broken lines in FIG. 4 and after finger 63 has been inserted into the associated slot 64 of its adjacent runner 11, T 41b then is pivoted downwardly as shown by the arrow in FIG. 4 until the slot 62 of the clip 47 functionally engages the associated finger 63. At this time the support legs 44, 45 of cross T 4lb will be adjacent the tile support legs 65 of runner 11 and the edge 47' of clip 47 will rest on flange 65.

it will be understood that nothwithstanding the interconnection between adjacent hangers through the runners in the manner heretofore set forth, a'significant degree of movement of the runners away from each other may be effected, due to the relative movement possible between the finger 63 and the socket 62.

The ability thus to move the components during installation of the hangers materially expedites the installation thereof since to provide additional clearance for the mounting of subsequent hangers or cross Ts it is merely necessary to modify the spacing between adjacent runners by exerting transverse pressure, and after the desired clearance is obtained, to insert the subsequent hanger, obviating the necessity for tilting, canting and prying encountered in the installation of grid structures heretofore known.

As best shown in FIG. 2, bracket 66 may be bolted, as by bolt 67, to the perimeter track 13, bracket 66 including a horizontal support surface 68, on which surface may be rested the end of the bottom portions of the cross T.

The grid structure, completed to the extent heretofore noted, has limited rigidity, due to the relative movability between the longitudinally directed runners 1] and the transversely extending cross Tees or hangers. Rigidity is provided by the cross struts 42 which will next be described.

Referring particularly to FIGS. 7 to 10, the cross struts 42, at their distal ends, are provided with locking clips which may be engaged with the runners 11, the connection between the cross struts and runners being effected without the use of tools, tightening of screws, etc. Since the locking clips 70 at each end of the cross struts are identical, a description of one will suffice.

The locking clips 70 preferably are formed of bent metal including attachment tab 71 fitting against web 72 of the cross struts, tab 71 being secured in position against the web 72 as by rivet 73. The clip includes a body portion 74, bent at right angles to the tab 7], the body portion 74 including upper and lower locking cars 75, 76 projecting above and below the surfaces of the struts.

The ears 75, 76 preferably include inwardly deflected frictional wedging elements 77, 78. A removable locator tab 79 extends from the attachment tab H a distance beyond the strut, the locator tab 79 being connected to the attachment tab 71 by a weakened neck 80.

The runners 11 along each side thereof include an upwardly extending lower locking flange 81 paralleling the web 22 adjacent the lower end of the web, and a downwardly extending upper locking flange 82 directed toward the flange 81. It will be observed that between the flange 81 and web 22 there is defined a vertically directed, upwardly opening slot 83. In similar fashion, there is defined between the web 22 and flange 82 a downwardly opening vertically directed slot 84. The pre-punched web portions 22 of the runners 1] are provided with a series of apertures 85, the apertures being spaced in accordance with the desired spacing of the cross struts 42.

In order to attach a cross strut in position between adjacent runners, locator tabs 79 are passed through the spaced locator apertures 85 in the pair of runners to be connected, with the ears 75, 76 offset from the locking ledges 81, 82. With the cross strut in the desired position, final attachment is made merely by rotating the cross strut about a horizontal axis through an are sufficient to cause the ears 75, 76 to enter into the slots 83 and 84, respectively, the ears being frictionally rotated within the slots by the locking wedge portions 77, 78 thereof.

As previously noted, the rotary movement is effective to engage a locking clip 70 at each end of the cross strut into interlocked relation with an opposed pair of runners. The length of the cross struts is calculated to maintain the precise desired spacing between adjacent longitudinal runners to accommodate the lengthwise dimension of the tiles T between adjacent runners.

Where additional rigidity is desired, an extra cross strut may be added at any point along the length of adjacent runners by merely breaking off the locator tab 79 at the weakened neck portion 80 thereof, whereupon it will be observed the attachment between a cross strut and runner may be effected without the ne cessity for the cross strut to be aligned with an aperture, such as an aperture 85 in the runner.

The ends of the cross struts adjacent the perimeter 13 may be connected thereto by sawing the strut to the approximate desired length, sleeving a right angle cross strut anchor 86 into the channel defined interiorly of the cross strut, the anchor including a right angular portion 87 which may be mechanically connected as by machine screw 88 to the perimeter track.

As is known, the perimeter track components or sections may be connected together by a series of connector splines 89 where longitudinal components of the tracks are to be secured together, the corners being coupled by right angle splines 90 (see FIG. 3).

It will be observed that following connection of the cross struts with the runners, the theretofore relatively flexible ceiling grid structure becomes extremely rigid. By this means it is possible to provide a temporary grid structure wherein the parts are disposed in the approximate desired ultimate position, with fine adjustments being accomplished, particularly in the connection to the perimeter, after the structure is essentially in position. Thereafter, the temporary and flexible grid structure is, by the insertion of the cross strut members, converted to a rigid, permanent structure, the final step of inserting the cross strut members being accomplished without the necessity for using tools, tightening bolts, etc.

By pre-punching locating slots along the length of the runners, arcuate positioning of the cross Tees supporting the tile edges is assured.

Similarly, since the cross Tees and support struts are factory formed to coordinate with the size of the tiles, the interconnection of the grid structure automatically results in an assemblage in which the tile support com ponents define therebetween tile receiving apertures of the precise size desired.

It will be readily recognized from the foregoing description that the grid, with minor modifications, may be rendered suitable for tiles other than those having the rabbetted edge configuration shown in the accompanying drawings.

Similarly, sectional details of the various components may be modified without departing from the spirit of the invention. Accordingly, the invention is to be broadly construed within the scope of the appended claims.

Having thus described my invention, what I claim as new and desire to secure by letters patent of the United States is:

1. An electrified hung ceiling grid construction comprising, in combination, a plurality of horizontally disposed parallel runner members supported in coplanar alignment from a building structure, said runner members including a vertically directed mounting web and horizontally disposed tile support flanges, upper and lower spaced locking flanges in proximate spaced rela' tion to and disposed on either side of said mounting web, said locking flanges and web defining vertically directed locking channels, a plurality of longitudinally spaced, transversely extending locator apertures formed in said mounting webs, cross strut means extending between adjacent runners and locking the same against relative transverse movement, said strut means including at their ends projecting tab members adapted to be inserted through said locator apertures, and adjacent the ends of said struts locking clip members including resilient locking means projecting beyond the upper and lower surfaces of said struts, said locking means being insertible into the space between said locking flanges and being extended into tightly wedged position within said locking channels responsive to rotation of said struts about their longitudinal axes, a plurality of tile support hangers extending between adjacent parallel runners, said support hangers including horizontally extending tile support ledges disposed in coplanar alignment with the tile support flanges of said runners, a plurality of alignment slots formed in said mounting webs of said runners, said slots being regularly spaced apart in accordance with the desired spacing of said hangers, complemental connector means on said hangers extending through said alignment slots and linking the distal ends of adjacent support hangers, said connector means including a finger on one said hanger slidably engaging a finger socket on the other said hanger, thus to permit relative horizontal movement between said adjacent hangers, the spacing between the clip members at opposite ends of said struts being coordinated with the length of said support hangers whereby, upon rotation of said struts into locking position, the ends of said ledges of said struts are tightly abutted against said flanges of said runners.

2. An electrified hung ceiling grid construction comprising, in combination, a plurality of horizontally disposed parallel runner members supported in coplanar alignment from a building structure, said runner members including a vertically directed mounting web and horizontally disposed tile support flanges, a plurality of regularly spaced apart alignment slots formed in said web, a plurality of tile support hangers extending between adjacent parallel runners, said support hangers including horizontally extending tile support ledges disposed in coplanar alignment with the tile support flanges of said runners, complemental connector means linking the distal ends of adjacent tile support hangers, said connector means extending through said alignment slots and providing a sliding connection between said adjacent hangers, and cross strut means extending between adjacent runners and locking the same against transverse movement, said cross strut means being insertible between adjacent runners and rotated into locking engagement with said runners, the length of said cross strut means and said hangers being coordinated to urge said ledges of said struts into tightly abutted engagement with said flanges of said runners responsive to rotation of said struts to said locking positionv 3. A device in accordance with claim 2 wherein said web includes spaced, transversely extending locator apertures and the ends of said cross strut means include projecting tabs adapted to be inserted through said apertures prior to rotation of said struts into said locking position. 

1. An electrified hung ceiling grid construction comprising, in combination, a plurality of horizontally disposed parallel runner members supported in coplanar alignment from a building structure, said runner members including a vertically directed mounting web and horizontally disposed tile support flanges, upper and lower spaced locking flanges in proximate spaced relation to and disposed on either side of said mounting web, said locking flanges and web defining vertically directed locking channels, a plurality of longitudinally spaced, transversely extending locator apertures formed in said mounting webs, cross strut means extending between adjacent runners and locking the same against relative transverse movement, said strut means including at their ends projecting tab members adapted to be inserted through said locator apertures, and adjacent the ends of said struts locking clip members including resilient locking means projecting beyond the upper and lower surfaces of said struts, said locking means being insertible into the space between said locking flanges and being extended into tightly wedged position within said locking channels responsive to rotation of said struts about their longitudinal axes, a plurality of tile support hangers extending between adjacent parallel runners, said support hangers including horizontally extending tile support ledges disposed in coplanar alignment with the tile support flanges of said runners, a plurality of alignment slots formed in said mounting webs of said runners, said slots being regularly spaced apart in accordance with the desired spacing of said hangers, complemental connector means on said hangers extending through said alignment slots and linking the distal ends of adjacent support hangers, said connector means including a finger on one said hanger slidably engaging a finger socket on the other said hanger, thus to permit relative horizontal movement between said adjacent hangers, the spacing between the clip members at opposite ends of said struts being coordinated with the length of said support hangers whereby, upon rotation of said struts into locking position, the ends of said ledges of said struts are tightly abutted against said flanges of said runners.
 2. An electrified hung ceiling grid construction comprising, in combination, a plurality of horizontally disposed parallel runner members supported in coplanar alignment from a building structure, said runner members including a vertically directed mounting web and horizontally disposed tile support flanges, a plurality of regularly spaced apart alignment slots formed in said web, a plurality of tile support hangers extending between adjacent parallel runners, said support hangers including horizontally extending tile support ledges disposed in coplanar alignment with the tile support flanges of said runners, complemental connector means linking the distal ends of adjacent tile support hangers, said connector means extending through said alignment slots and providing a sliding connection between said adjacent hangers, and cross strut means extending between adjacent runners and locking the same against transverse movement, said cross strut means being insertible between adjacent runners and rotated into locking engagement with said runners, the length of said cross strut means and said hangers being coordinated to urge said ledges of said struts into tightly abutted engagement with said flanges of said runners responsive to rotation of said struts to said locking position.
 3. A device in accordance with claim 2 wherein said web includes spaced, transversely extending locator apertures and the ends of said cross strut means include projecting tabs adapted to be inserted through said apertures prior to rotation of said struts into said locking position. 